Method of forming hollow articles of plastic material



vJune 30, 1942. .1. R. HoBsoN METHOD OF FORMING HOLLOW ARTICLES OF PLASTIC MATERIAL Filed May 13, 1938 3 Sheets-Sheet l v ....II |I....|\\..Il l l n l June 30, 1942. J. R. HoBsON METHOD OF FORMING HOLLOW ARTICLES OF PLASTIC MATERIAL Filed May 13, 1938 5 Sheets-SheenI 2 S SSS SSSS www? x? A@ e Wess Wam/W June 30, 1942. J. R. HOBSON METHOD OF FORMING HOLLOW ARTICLES OF PLASTIC MATERIAL Filed May 13, 1938 :s sheets-sheet s [2z wei@ zo 2 Jb IZ. 5705502@ r-@M/W eys PM Jue 30,1942

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Delaware AnlitionlayllmselllNO-mm naar.. 11:45) v lhisinventionvrelatestomethodsofforming lmllowarticlesoforganieplastiemateriaLThe invenisdirectedtotheworkingoforganic plastiematerialasuchascelluloseacetateand otherorganicthermoplasticabntisnotlimited as containers with necks of exact dimensions adapted to be fitted with typeofcaporclosuresuchasastandardcapor closure nowusedonother kinds oi'hollowobiectsinsuchamannerastopermit control of the shape. sisel and distribution of material in. such portion ofthe articles.

The inventionirot particular utility in, though not limited to, the manufacture of hollow articles lnvingnarrowneckathatiainwhichthenecks .ofthearticlesarenarrowerlndiameterthanthe diameter of the body portions of the articles.

Broadly considered, the invention involves the initial formation of the neck or neck iinish of an article by "injection molding and the subsequent iormation of the body portion of the article by "extrusion" and shaping of additional material;x for example, by blowing.

The term injection molding, or variations of tuch term, means the'introduction under pressure oi organic material, made plastic by heat or lmat and pressure, into a mold cavity closed except where the material enters and which cavity, therefore, exactly determines the size and shape oitheportionoithearticleiormedtherein. The term extruding or extrusion or variations thereof, means the feeding of such material underpressureandinplasticorworking condition while only partly confined or unconiined by mold-l surfaces. m8The invention may more clearly be understood from the following detailed description of the embodiments of the invention illustrated in the accompanying drawings, in which drawings:

l'igurcs1to6,inclusive.areviewsincentral verticalaection ngsfvnaneiwvemnmuarvimmustratingmodiilcationsoftheapparatusandmethod showninFlgs. 1 too; and

liga.l2to17inclmiveareviewsinvertical Referringtoligs. 1to6,theapparatusshown comprises an extruding device or nonle indicated generally Il adapted to cooperate therewith. -The'extruding device or nozzle l2'is associated with suitable apparah (not shown) for supplying organic plastic material in plastic or working condition. Such apparatus does not constitute part of this invention and is omittedV to simplify the illustration and description of the invention. Said device comprises an outer. double-walled sleeve Il in which a space or chamber I5 is formed for receiving a temperature-controlling medium. Within sleeve Il is the hollow plunger II which is spaced from the sleeve to provide a tubular passage for plastic material. as indicated at I1. Plunger I6 contains chamber Il for receiving a temperature controlling medium through a pipe I! in said chamber. 'Ihe head 2| of plunger Il isintbeformofavalve or cut-oil' which is adapted to engage a seat 22 in the bottom of sleeve Il.

'Ihe mold unit Il is divided horizontally into three shoulder) mold, Ilb the body mold and section l3c the bottom mold. Each of said sections prei'- erably is divided vertically into sections mounted on hinge pins (not shawn) for opening and closing operations.

Section I3a has the neck iinish portion 2l which is surrounded by passages 23a, and shoulder portion 24 surrounded by passages 24a, the passages receiving temperature controlling fluid. The neck portion 2l receives neck pin 25, collar 26 of which iits tightly against mold section IIa. Neckpin lialsohasacentralblowingairpassage 21.

The bottom of sleeve Il is tapered at Ila to seat tightly on the bottom of mold portion 24 and head 2| of plimger I6 is iiat and seats on neck pin 25 to close the passage 21 therein.

Therbody mold section IIb is recessed at 2l to receive the section avtherein and has a boss 29 which is iitted into the bottom mold section llc. Sections IIb and llc have passages 2| and V32 for oflpparatmforcan'yingout thexnetlioddepictedlnseveralstepsinsaid at l2 and an invertedmold unitV sections, section Ila being the neck (and the circulation of temperature-controlling medium therethrough.

Section I3c has opening 33 therein to provide a sliding fit with sleeve I4 The outside diameter of extruding device I2 is made small to reduce the diameter of opening 33. The internal diameter of sleeve I4 is proportioned to the diameter of the neck finish portion 23, being of substantially equal diameter at its tip as indicated at 34 and somewhat less diameter above its tip.

In performing my novel method with the above described apparatus, the parts are assembled as illustrated in Fig. l, and plastic material is introduced under heat and pressure into the extruding device I2, as indicated at l1. Circulation of temperature controlling medium through chamber I5 of sleeve I4 and through plunger I6 maintains the material in plastic working condition. Such material now is injected into the neck finish mold portion at 23 around neck pin 25 to form the neck finish portion 35 of the article being made. Cooling medium preferably is circulated through passage 23a at this time to set and complete the formation of the neck finish at least sufficiently to prevent it from sticking to neck pin which is now lowered into the-position shown in Fig. 2.

It will be observed that the engagement of neck pin 25 and the head 2I of. plunger 26 prevents formation of a fin racross the interior of the neck finish.

Operations are now performed to develop the shoulders and body of the article. Beginning with the parts in the positions of Fig. 3, relative bodily axial movement of the extruding device I2 and mold unit is eilected to withdraw the device from the unit. During such withdrawal device I2 is maintained in axial alignment with mold unit I3 by mold bottom I3c and by supports (not shown) for the device and mold unit. During this operation, additional material may be extruded from the device I2 and air may be admitted through passage 21 of neck pin 25 to expand the plastic material into contact with the shoulder mold portion 24 and the body mold portion I3b (see Fig. 3) as the material is being extruded from the extruding device I2. There is thus formed shoulder portion 36 andv body portion 31. 'Ihe extruding, blowing and withdrawal of device I2 are continued until the body portion 31,is completed.

Finally, the outer annular portion 38a of the bottom of the article is formed against bottom mold I3c. To accomplish this, the speed of withdrawal of the device I2 may be reduced or withdrawal stopped, so that blowing and stretching of the extruded material will reduce its thickness.

To complete the formation of the bottom ofthe article, the bottom mold I3c may be withdrawn and the tubular connection between the portion 38a and the material in device I2 necked-in by a constricting means, closed and severed. As illustrated in Fig. 4, this may be accomplished by employing a pair of V-notched shears 39 which may be closed as the device I2 and mold I3 relatively move into the positions shown. This results in the formation of an outwardly extending, roughly conical, bottom portion 38h and a closed end I1a on the tubular material I1 in device I2. During this part of the operation, the fiow of air through neck pin 25 may be interrupted.

Portion 38h may be pushed inwardly of the plane of the bottom ofthe article and bottom mold I3c replaced, as shown in Fig. 5, in preparation for a blowing operation. End portion |1a may now be cut oil by closing seating plunger I3, as also shown in Fig. 5. The portion I 1a may be discarded as scrap.

To complete the formation of the bottom of the article, the conical portion 38h may, if necessary or desirable, be reheated by av burner or other heater (not shown) and either opening 33 in bottom mold I3c closed by a plug or disk (not shown) or the bottom mold I3c replaced by a mold bottom I3d, as shown in Fig. 6. Bottom mold I3d may be chambered, as shown at 32b, to receive a temperature-controlling medium. Air may now be admitted through passage 21 in neck pin 25 to blow out portion 38h and thus complete the bottom of the article, as indicated at 38 in Fig. 6.

During the operation of extruding and expanding, the mold portions I3, I3b, I3c and I3d preferably are cooled suiilciently to set the plastic material as it attains the shape of the molding surfaces. However, the cooling of mold bottom I3c should be moderate in order not to cool portion 38h to such an extent as to make too difficult the reheating and blowing out of this portion.

In the development of the article, the proper or desired time relation between extruding, withdrawing and blowing is maintained by suitable timing means (not shown) to secure the desired distribution of material in the shoulder, body and bottom portions of the article. Each of such operations may be continuous or periodic and may be simultaneous or timed to occur at different times during the formation of an article. By cooling the material as it is expanded into engagement with the mold wall, stretching or drawing of material thereabove may be effected by withdrawal of device I2 to assist in obtaining the desired wall thickness.

Wall distribution also may be controlled by varying the amount of material extruded as. by movement of plunger I6 relative to sleeve I4 to move valve head 2I towardfor away from the seat 22. Suitable mechanism (not shown) also may be provided for this purpose.

Instead. of blowing out the material as it is being extruded, as illustrated in Fig. 3, blowing may be delayed until the nozzle I2 is in raised position. In this way, a tube may be formed of substantial length by extrusion which will be held in axial position betweenl the nozzle and neck mold. After the desired length of tube thus is formed out of contact with the mold sur faces, it may be blown out by air. However, `the blowing operation has to be performed before the nozzle I2 is disengaged from the opening in bottom mold 32.

In the modification illustrated in Figs. 7 to 11 inclusive, the neck iinish'and shoulder portions are formed by injection molding, body portion of the article is formed by extrusion without substantial expansion, and the bottom is formed by inserting a disk in the open end of the article and sealing it therein,

In these figures, the extruding device 1s indicated generally at 4Ir and themold unit at 42. The device 4I comprises a hollow plunger 43 having a central tube 44 which forms a chamber 45 for temperature controlling medium. Surrounding the narrower upper lportion of plunger 43 is a sleeve 46 which is spaced from the plunger to provide for the passage of plastic material 41 in tubular form. 'I'he bottom end 46a of sleeve 4B is adapted to act-as a cut-oirfor the material in.

` of V-shape in cross-section, as indicated conjunction with a shoulder 4l formed on the plunger where the plunger is of slightly increased diameter. 'I'he lower end oi' plunger 43 is rounded, as shown at 43, to form the interior of the shoulder portion of an article, as hereinafter explained.

l The device 4I which comprises the plunger and sleeve is mounted for reciprocation in acasing Il containing a chamber 52 for temperaturecontrolling medium. 'I'he bottom of casing 5l is recessed at 53 to receive the boss 54 formed lon themold unit 42 to align axially the mold unit and extruding device.

The mold unit 42 is divided vonly vertically in this case and is chambered at 5l to receive a temperature-controlling medium. The inner wall of the mold has the neck iinish portion 42a, shoulder portion 42h and body portion 42c which terminates at its upper end in a recess or at 42d.

A neck pin 55 cooperates with vthe neck mold portion 42a to form the neck of an article. This neck pin 55 has a collar 55 therein which engages the bottom of mold end is made fiat to form a tight nt against the bottom of plunger 43, as indicated at 51, Fig. 7. Neck pin 55 also is chambered, as shown at 53, to receive a temperature-controlling medium.

In performing my novel method with the apparatus just described the mold unit 42 is engaged with the casing 52, as shown, and neck pin 55 is seated as shown in Fig. 7. Ihe extruding device 4I is now moved downwardly into the mold unit until plunger 43 engages neck pin 42 and sleeve 43 is moved upwardly to permit plastic material to be injected under heat and pressure into the mold around the rounded end 43 of plimger 43 and into the neck mold portion 42a oi' the mold unit. This forms the neck or finish 53 and shoulder 60 of an article by injection molding.

'111e extruding device 4| is now raised while the extrusion of plastic material is continued,` to form the body portion 6I of the article. See Fig. 8. During this operation, air may be admitted to the mold through tube 44 of plungerA 43 to slightly expand the tubular material 41 to form body portion 6I and to insure that the shoulder Il and portion 5| will be held in place against the mold wall. As the device 4I is moved out of the mold, sleeve 46 is moved down at the proper time to cut oi the material in the mold from the material 41 in the device.l Air pressure in the mold blows the material into the groove 42d, thus forming anges 62a52b on the open end of the article which provide a groove 52 therein.

'Ihe mold unit 42 now is disengaged from casing 52, neck pin 55 withdrawn andthe openended article withdrawn. To clo the open end of the article a disk or bottom 53 is placed in groove 32 and sealed therein by heat and pressure. 'I'he sealing of the bottom may be accomplished by engagement with a plate 54, Fig. 10, having a chamber 5I therein to receive a heating medium. This serves to squeeze flanges 52a- 52b together, as shown in Fig. 1l, thus sealing the disk 53 in place and completing the bottom of the article. The disk 63 may be heated to render it plastic before its insertion and this preheatlng may be conned to the edge of the disk.

It will be understoodthat the temperature of the extruding device is controlled to maintain the material to be extruded in plastic working condition, while the mold temperature is regulated so as to cool the material sumciently tol groove.

unit 42 and its inner' prevent it from stickingl to the plunger as the plunger is withdrawn and to set the material,

Y although sticking is prevented to some extent by the pressure of air thereon. I! the material is not set suiiiciently during the formation of the article, it may be cooled to a lower temperature in the mold before removal therefrom,

'I'he distribution of material in .neck 53 and shoulder 5l is determined by the size and shape of the cavity fonned between the corresponding molding surfaces of mold unit 42 and plunger 43. The maximum diameter of plunger 43 de'- termines the maximum thickr'iessV of wall portion 6I above the shoulder and this thickness may be diminished by restricting the flow of material between the end 45a of sleeve 46 and shoulder 48 of plunger 43, as device 4| is withdrawn to stretch or draw out the wall portion during its formation.

Suitable mechanism may be provided for operating the varlous parts of the apparatus in the desired time relation.

In the modified form of the invention illustrated in Figs. 12 to 17, apparatus is provided which comprises a mold unit 13, an extruding nozzle or device 1I and a finishing blow mold 12.

Mold unit 15 comprises a neck mold 13 and a neck pin or plunger 14 which is centered in the neck mold cavity 15 by a ring or closure 15 which closes the neck mold cavity. as shown. Neck mold 13 preferably is made in halves for opening and closing and is chambered as shown at 13a to receive a temperature controlling medium. The device 1| is similarly chambered at 1|a.

Neck pin or plunger 14 is made hollow and has a pointed tip 11 which constitutes a valve seatlng on the end of the plunger and having a stem 18, the collar 19 of which acts as a Stop against a spider III in the end of the plunger.

Blow mold 12 also is made in sections and has chamber 12a for temperature controlling medium. The top of this mold is recessed at 8| to receive and center neck mold 13.

1n making articles with scribed, plastic material and pressure in a solid stream or rod. Initially, the mold unit 13 is moved into engagement with nozzle 1I and plastic material is injection molded in the neck mold cavity about neck pin 14 which forms an initial opening in the neck portion 32 of an article being produced. During this and ensuing operations, the neck pin may be rotated or. oscillated continuously or intermittently. When the neck 82 is molded, it is moved downwardly axially of nozzle 1I Vand additional material is extruded, as shown at 33a, Fig. 13. Following this step, neck pin 14 may be forced upwardly through the neck mold 13 to lengthen the initial opening and carry it into the material 83 thereabove. This may result in the formathe apparatus last deis supplied under heat tion of an enlargement or bulge 33h, Fig. 14. The

neck pin 14 may now be lowered slightly relative to the neck mold and the entire lmit further lowered and air admitted into the neck pin which enters the initial opening and expands the extruded material to form a hollow blank, as shown at 83e. When the desired amount of material has been from the supply, as shown in Fig. 15.

The blank may now be further developed by rotating, swinging and blowing, or merely by suspending the blank and expanding it under the iniiuence of Agravity to a blank form, such as shown at 33d, Fig. 16. This ligure shows the suspension of the blank by the neck mold in the extruded, a knife 34 severs the blank` closed blow mold in which it may be blown to final Y ferm by admission ofair through the neck pin.

Thus there is formed an article having a narrow neck 82 and wide body portion 83. as shown in Fig. 1'?.

Suitable means (not shown) may be provided for voperating thevarious parts in'suitably timed relation and the temperature of the various-parts may suitably be regulated. The neck mold preferablyis cooled 'throughout the operation to set the neck portion 82. Blowing air preferably is heated to assist in keeping 'the materialplastic. The blow mold 12 preferably is cooled. The nozzle 'Il is always heated. The cooling effect of neck pin tip 11 is offset by the natural reheating of thematerial contacted bythe tip vand by the heated air applied to such material.

The development of the blank to the desired shape may be assisted by upward movement of the mold unit,. which will thicken the blank, especially if additional'material is extruded during such movement.

Variations or changes may be made in the details of construction and in the method without departing from the scope of the claims. Although the forms of the invention shown in Figs. 1 to 11 have been described with relation to the formation of articles in molds having the shape of the finished articles, it may also be used for making blanks or preshaped` articles to be completed in other molds by blowing or other methods of enlarging or forming preshaped articles of plastic materiahas illustarted for example `in Figs. 12 to 17. Therefore, the word article" as used in the claims is notlimited to nished articles but also applies to partially formed or incomplete articles or blanks.

The term body portion of an article as used in the claims means either the body portion or both the body portion and shoulder portion as separately referred to above except wherer the shoulder and body portions are specifically and separately referred to in said claims.

The embodiments of the invention which have been illustrated and described herein are particularly adapted to the formation of hollow articles from organic materials of the thermoplastic type of which cellulose acetate is an-example. The invention may be employed in working cellulose derivatives such as cellulose esters and celluf lose ethers as well as natural or synthetic gums or resins of either the thermoplastic or thermosetting type or mixtures thereof.

The temperatures of the various parts of the apparatus will be controlled or maintained in accordance with the properties of the organic material being worked. Thus in working thermoplastics, the parts will Abe heated where necessary or desirable to make the material plastic or workable and cooled lto cause the material to set or harden; in working Ithermosetting materials, the parts may be heated to make the material plastic and workable initially, cooledl (or unheated) to maintain plasticity or a semi-cured condition for further working and heated to set or harden thel material.

Having thus described my invention, what .I claim is:

1.- The method of forming hollow articles of organic plastic material which comprises -first forming the neck of lan article by injection moldlng of such material and then forming the body portion of said article by extruding and shaping additional material integral with the neck. of said article.

2. The' method of forming hollow articles of organic 'plastic material which comprises first forming the neck of an article by injection molding of such material and then forming the body portion of said article by extruding and expanding additional material integral with the neck of said article.

3. The method of forming hollow articles of organic plastic material which comprises feeding such material from an extruding device into the neck forming portion of a mold unit and injection molding such material therein to form the neck portion of an article, and subsequently extruding additional material from said devicev into a body forming portion of said mold unit and shaping it therein to form the body portion of said article integral with the neck thereof.

4. The method of forming hollow articles of organic plastic material which comprises engaging an extruding device and neck forming mold, feeding material through said device and injection molding the neck portion of an article in said mold, and forming the body portion of said article by axially disengaging said device and neck forming mold, extruding additional material through said device, and shaping said additional material into the body portion of said article integral with theneck thereof.

5. The method of forming hollow articles of y organic plastic material which comprises feeding such material in tubular form through an extruding device and injectionmolding the neck of an article in a neck forming mold, axially separating said device and neck mold-while exrial in a neck forming portion of a mold unit to form the neck of the article, withdrawing said device from said unit and extruding additional material therefrom in tubular form. during such withdrawal and simultaneously admitting air to the interior of said material to shape it in contact with a body forming portion of said mold unit to form the body portion of the article integral with the neck thereof, and closing one end of such body portion to form the bottom of the hollow article.

7. The method of forming hollow articles of organic plastic material which comprises feeding such material in tubular form through an extruding device while holding said device in engagement with a neck forming portion of a mold unit and injection molding the neck of an article, withdrawing said device from said unit While extruding additional material and expanding such material into contact with a body mold portion of said unit to form the body portion of said article integral with the neck thereof, and into contact with a bottom forming portion of said unit to partially form the bottom of the article, closing the tubular material and severing the molded portion thereof from the supply to roughly form the central bottom portion of the article. and blowing the roughly formed bottom portion to final shape.

8. The method of forming hollow articles of organic plastic material which comprises injection molding the neck and shoulder portions of an article, and extrusion molding the body portion of said article integral with the neck and shoulder portions of said article.

9. The method of forming hollow articles of organic plastic material which comprises feeding such material from an extruding device into a neck mold and injection molding the neck of an article, axially separating the device and mold, extruding and expanding into hollow blank form additional material integral with the neck of said article to provide a hollow blank, and blowing the blank to nal form.

10. The method of forming hollow articles of organic plastic material which comprises engag ing a neck mold with an extrusion device, injection molding the neck finish of an article in said neck mold, axially separating said neck mold and device, extruding additional material in solid cross section for the body portion of said article integral with the neck finish thereof, expanding said additional material to hollow form to provide a blank, and blowing the blank to the final form of said article.

1l. The method of forming hollow articles of organic plastic material which comprises rst forming the neck of an article by injection molding of such material, then forming the body portion of said article by extruding and shaping additional material integral with the neck of said article, and closing one end of said body portion to form the bottom of the hollow article.

JOHN R. HOBSON. 

